qleem

For pics, see https://www.cherokeeforum.com/f2/idl...76/#post895834 and http://www.jeepforum.com/forum/f9/cl.../#post10277391

This writeup is just to add some info that I didn't know/ couldn't find when I was researching the job.

For 98 XJ 4.0 I6

Fastener and gasket info:

All 3 cables (from front to back transmission, speed control, and accelerator, in my case) snap off. The two black plastic connecters can be pushed with a screwdriver in vector with cable extension. The 3rd (accel) pries off orthogonally to the plane of the cable

Air hose
Install and remove clamps with channel lock pliers

Throttle body to manifold
10mm bolts with captive washer. Torque 11Nm. Short extension req'd
Gasket is single use. I replaced with Fel-Pro 60948 - $5 on amazon

MAP sensor to throttle body
T25 Torx. Torque 3Nm

IAC motor to throttle body
T20 Torx. Torque 7Nm
Small o-ring should be ok to reuse, but remove before cleaning

IAC housing casting to throttle body
T20 security Torx. Torque unknown. Aluminum to aluminum w/ gasket, I went to about 7Nm
Gasket is paper and should not be reused. I rebuilt with Permatex 80017
I would recommend removing this if you have the tools and gasket/maker. The sprue flash from the casting is right next to the IAC port, leading to a lot of gunk building up there

I didn't mess with the TPS, but from FSM:
"The TPS must be installed so that it can be rotated a few degrees. (If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs). The TPS will be under slight tension when rotated."
Torque 7Nm. Torx 20 or 25 I believe.

Where specified, torque is from the 97 xj FSM

Happy to report the cleaning fixed my stumbling idle

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